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Home >> Suzuki >> 2004 >> Swift + >> Repair and Diagnosis >> External Pages >> Different car >> Section 87 (Hydraulic Brake System) >> Repair Instructions >> Master Cylinder Overhaul >> Assembly Procedure
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Assembly Procedure

WARNING: This page is about a different car, the 2008 Suzuki Swift +, 2008 Pontiac Wave, and 2008 Chevrolet Aveo. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View of Primary Piston and ABS Master Cylinder Body
    GM1245646Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Brake Fluid Caution .
    NOTE: Do not hone the master cylinder bore. When the brake master cylinder is overhauled, it is recommended that the cylinder body be replaced rather than CLEANED UP by honing the bore. The master cylinder has a hard, highly polished BEARINGIZED surface, which is produced by diamond boring followed by ball or roller burnishing under heavy pressure. Honing will destroy this hard smooth surface and cause rapid wear of the rubber cups.
    NOTE: Use only approved solvents when cleaning or flushing the master cylinder and related components. Solvents which contain traces of mineral oil or other contaminants will damage the rubber parts in the system.
  1. Clean the parts with denatured alcohol or clean brake fluid. Dry the parts with compressed air.
  2. Inspect the master cylinder bore for scoring or corrosion. If scoring or corrosion is evident, replace the master cylinder body.
  3. Lubricate the master cylinder bore with clean brake fluid.
  4. Carefully insert the secondary piston assembly bore until the secondary piston contacts the base of the cylinder body. Use a wood or a plastic drift, if necessary.
  5. Insert the primary piston.
    6. Fig 2: View of Retaining Ring & Non-ABS Cylinder Body
    GM1245644Courtesy of GENERAL MOTORS CORP.
  6. Press the pistons into the cylinder bore using a wooden or a plastic drift. The non-ABS cylinder body is shown.
    7. IMPORTANT: When installing the new retaining ring, take care not to damage the cylinder bore.
  7. Insert the new retaining ring into the groove in the cylinder bore. Remove the welding rod.
  8. Move the pistons backward and forward after installation in order to inspect for free movement.
    9. Fig 3: View of Master Cylinder, Brake Fluid Reservoir, and Seal Ring
    GM1245639Courtesy of GENERAL MOTORS CORP.
  9. Lubricate the seal ring and insert the seal on the shaft into the cylinder bore. The open side must face outward until the seal rests on the piston.
  10. Install the brake fluid reservoir to the master cylinder. Refer to Master Cylinder Reservoir Replacement .
  11. Install the master cylinder assembly. Refer to Master Cylinder Replacement .
  12. Bleed the braking system. Refer Hydraulic Brake System Bleeding (Manual) .
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